ESAB Origo Mig C420 PRO User manual

Valid for serial no. 6270349 301 112 070104
Mig C420 PRO
Mig C420w PRO
Origo
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
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Instruction manual

ENGLISH
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TOCe
1 DIRECTIVE 3........................................................
2 AFETY 3...........................................................
3 INTRODUCTION 5...................................................
3.1 Equipment 5................................................................
4 TECHNICALDATA 5.................................................
5 IN TALLATION 6....................................................
5.1 Placing 6...................................................................
5.2 Assem lyofcomponents 7...................................................
5.3 Electricalinstallation 7.......................................................
5.4 Mainspowersupply 8........................................................
6 OPERATION 8.......................................................
6.1 Connectionandcontroldevices 9.............................................
6.2 Weldingwithoutgas 10.......................................................
6.3 Wirefeedpressure 10........................................................
6.4 Replacingandinsertingwire 10................................................
6.5 Start 11.....................................................................
6.6 Overheatingprotection 11.....................................................
6.7 Waterconnection 11..........................................................
6.8 Waterflowguard 11..........................................................
6.9 Idlemode 11................................................................
6.10 OrigoTM Mig C420w PRO / OrigoTM Mig C420 PRO 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 12....................................................
7.1 Inspectionandcleaning 12....................................................
7.2 Toppingupthecoolant 13.....................................................
8 FAULTTRACING 13...................................................
9 ORDERINGOF PAREPART 13......................................
DIAGRAM 14............................................................
ACCE ORIE 20.......................................................

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1 DIRECTIVE
DECLARATION OF CONFORMITY
ESAB AB, Welding Equipment, SE--695 81 Laxå, Sweden, gives its unreserved guarantee that weld-
ing power source OrigoTM Mig C420 PRO, OrigoTM Mig C420w PRO from serial num er 627 complies
with standard IEC/EN 60974--1, in accordance with the requirements of directive (73/23/EEC) and
addendum (93/68/EEC) and with standard IEC/EN 60974--10 in accordance with the requirements of
directive (89/336/EEC) and addendum (93/68/EEC).
--------------------------------------------------------------------------------------------------------------------------------------
Kent Eim rodt
Glo al Director Equipment and Automation
ESAB AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2006--09--05
2 AFETY
Users of ESAB welding equipment have the ultimate responsi ility for ensuring that anyone who
works on or near the equipment o serves all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen-
dations should e o served in addition to the standard regulations that apply to the workplace.
All work must e carried out y trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must e familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding
2. The operator must ensure that:
Sno unauthorised person is stationed within the working area of the equipment when it is
started up.
Sno--one is unprotected when the arc is struck
3. The workplace must:
Se suita le for the purpose
Se free from draughts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
SDo not wear loose--fitting items, such as scarves, racelets, rings, etc., which could ecome
trapped or cause urns.
5. General precautions
SMake sure the return ca le is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must e clearly marked and close at hand.
SLu rication and maintenance must not e carried out on the equipment during operation.
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WARNING!
Read and understand the instruction manual
efore installing or operating.
WARNING
READ AND UNDER TAND THE IN TRUCTION MANUAL BEFORE IN TALLING OR OPERATING.
ARC WELDING AND CUTTING CAN BE INJURIOU TO YOUR ELF AND OTHER . TAKE PRECAU-
TION WHEN WELDING. A K FOR YOUR EMPLOYER’ AFETY PRACTICE WHICH HOULD BE
BA ED ON MANUFACTURER ’ HAZARD DATA.
ELECTRIC HOCK -- Can kill
SInstall and earth the welding unit in accordance with applica le standards.
SDo not touch live electrical parts or electrodes with are skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUME AND GA E -- Can be dangerous to health
SKeep your head out of the fumes.
SUse ventilation, extraction at the arc, or oth, to take fumes and gases away from your reathing zone
and the general area.
ARC RAY -- Can injure eyes and burn skin.
SProtect your eyes and ody. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect ystanders with suita le screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflamma le materials near y.
NOI E -- Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn ystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOUR ELF AND OTHER !
Do not use the power source for thawing frozen pipes.
WARNING!
This product is solely intended for arc welding.
Do not dispose of electrical equipment together with normal waste!
In o servance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must e collected separately and returned to an
environmentally compati le recycling facility. As the owner of the equipment, you should
get information on approved collection systems from our local representative.
By applying this European Directive you will improve the environment and human health!
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3 INTRODUCTION
The OrigoTM Mig C420 PRO, OrigoTM Mig C420w PRO are step--controlled compact welding power
units incorporating wire feed mechanism intended for MIG/MAG welding with solid wires of steel,
stainless steel or aluminium, and cored wires with or without shielding gas.
The OrigoTM Mig C420w PRO are equipped with cooling liquid system for welding torch. The OrigoTM
Mig C420 PRO are not equipped with cooling system and can operate only with appropriate gas
cooled torches.
The power units are fan--cooled and equipped with thermal overload protection.
The machines can e fit with a flow guard (OrigoTM Mig C420w PRO).
E AB’s accessories for the product can be found on page 20.
3.1 Equipment
The power source is supplied with:
SWelding gun PSF 410W -- 4,5m
SReturn ca le 5m with return clamp
SShelf for gas cylinder
SInstruction manual
4 TECHNICAL DATA
OrigoTM Mig C420 PRO / OrigoTM Mig C420w PRO
Voltage 400--415V, 3∼
∼∼
∼50Hz
Permissible load
at100 % duty cycle 315 A/30V
at 60 % duty cycle 400 A/34V
at 50 % duty cycle 420 A/35V
etting range (DC) 50A/16,5V--420A/35V
Open circuit voltage 14--47V
Open circuit power 520W
with cooling unit 730W
Efficiency at max current 77%
Power factor at max current 0,92
Control voltage 42V, 50/60Hz
Wire feed speed 1,9 -- 25,0m/min
Burnback time 0 -- 0,5s
Creep start OFF / ON
2/4 stroke 2 / 4
Welding gun connection EURO
Max diameter of wire bob-
bin 300mm
Wire dimension range 0,6 -- 1,6mm
Dimensions lxwxh 935 x 640 x 800mm
Weight 215kg
with cooling unit 230kg
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Operating temperature --10 to +40oC
Enclosure class IP 23
Application classification
Cooling unit
(100 % duty cycle)
P1l/min 1200 W @ 25˚C
pmax 3,5 ar
Coolant 50 % water / 50% glycol
Coolant quantity 5,5 l
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-
tain load without overloading.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration y solid
o jects or water. Equipment marked IP23 is designed for indoor and outdoor use.
Application class
The sym ol indicates that the power source is designed for use in areas with increased
electrical hazard.
5 IN TALLATION
The installation must be executed by a professional.
ote!
Connect the power source to the electricity mains with a network impedance of 0.268 Ω or lower. If the
network impedance is higher, there is a risk of flicker in the illuminators.
WARNING!
This product is intended for industrial use. In a domestic environment this product may cause radio
interference. It is the user’s responsi ility to take adequate precautions.
5.1 Placing
Position the welding power source such way that its cooling air inlets and outlets are
not o structed.
The power supply should e lifted y means of its lifting
eye. The handle is only intended for pulling it along the
ground.
Lifting instructions
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5.2 Assembly of components
During transport, the rear wheels of the power source are in their forward position.
Before use, place the wheels in their rear position.
WARNING!
5.3 Electrical installation
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5.4 Mains power supply
Check that the unit is connected to the correct mains power supply voltage, and that
it is protected y the correct fuse size. A protective earth connection must e made,
in accordance with regulations.
Rating plate with supply connection data
3∼50 Hz
Voltage V 400/415
Current A
at100% duty cycle 19
at 60% duty cycle 27
at 50% duty cycle 30
Cable area mm2
22
24 x 4
Fuse, slow A 25
B: The mains cable areas and fuse si es as shown above are in accordance with Swedish
regulations. They may not be applicable in other countries: make sure that the cable area and fuse
si es comply with the relevant national regulations.
6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
WARNING!
Rotating parts can cause injury, take great care.
To prevent the reel sliding off the hu : Lock the reel in place y turning
the red kno as shown on the warning la el attached next to the hu .
WARNING!
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WARNING -- TIPPING RI K!
There is a risk of tipping while transportation and operation, if the welding machine leans
more than 10o. In that case appropriate securing has to e provided !
6.1 Connection and control devices
1Mains supply switch 10 Connection for return ca le (--), medium in-
ductance
2Switch, coarse control 11 Connection for return ca le (--), low induc-
tance
3Switch, precise control 12 Kno for wire speed setting
4Indicating lamp, power supply ON 13 Kno for selecting 2/4--stroke control mode
5Orange indicating lamp, overheating and
loss of coolant* 14 Kno for selecting -- creep start -- ON/OFF
6EURO -- connector (for welding gun) 15 Kno for urn-- ack time setting
7Connection for cooling water to the welding
gun (Blue -- with ELP** switch) 16 Digital instrument -- V / A (option,see page 20)
8Connection for cooling water from the weld-
ing gun (Red) 17 Water flow guard (option,see page 20)
9Connection for return ca le (--), high induc-
tance
* Indicating loss of coolant, only when water flow guard is used, see point 6.8
** ELP = ESAB Logic Pump, see point 6.7.
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6.2 Welding without gas
6.3 Wire feed pressure
Start y making sure that the wire moves smoothly through the wire guide. Then
set the pressure of the wire feeder’s pressure rollers. It is important that the
pressure is not too great.
Fig 1 Fig 2
To check that the feed pressure is set correctly, you can feed out the wire against
an insolated o ject, e.g. a piece of wood.
When you hold the gun approx. 5 mm from the piece of wood (fig. 1) the feed
rollers should slip.
If you hold the gun approx. 50 mm from the piece of wood, the wire should e
fed out and end (fig. 2).
6.4 Replacing and inserting wire
SOpen the side panel.
SDisconnect the pressure sensor y folding it ackwards, the pressure rollers
slide up.
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SStraighten out the new wire 10--20 cm. File away urrs and sharp edges from the
end of the wire efore inserting it into the wire feed unit.
SMake sure that the wire goes properly into the feed roller track and into the outlet
nozzle and the wire guide.
SSecure the pressure sensor.
SClose the side panel.
6.5 tart
When switched on, indicating lamps [4,5] are on for 2 seconds. Normally, if the
machine is not overheated, it should start to work in idle mode, which is indicated y
linking of the supply ON lamp. The fan and the coolant pump are stopped. The fan
starts at the first start of welding. The coolant pump starts at the same moment, if it
is switched on with ELP switch on the water outlet [7].
6.6 Overheating protection
The power source has 2--step control of fan speed and overheating protection.
If temperature crosses the threshold point, the fan starts to run with increased
speed. If the internal temperature ecomes too high, the welding is interrupted and
disa led. This state is indicated y permanent lighting of the orange indicating lamp
on the front of the unit. It resets automatically when the temperature falls down.
6.7 Water connection
The OrigoTM Mig C420w PRO have a sensor ELP, ESAB Logic Pump, which senses
whether the water hoses of the welding gun are connected. When a water cooled
welding gun is connected, the water pump is active.
It is recommended to switch the power source off y means of the mains switch
ON/OFF [1] for connecting the cooling water hoses to/from the OrigoTM Mig C420w
PRO.
6.8 Water flow guard
The machines with cooling unit (OrigoTM Mig C420w PRO) can e fit with a water
flow guard (option -- see page 20).
The water flow guard interrupts and disa les the welding in event of loss of coolant.
This state is indicated y linking of the orange indicating lamp on the front of the
power source. If there is a lack a coolant flow, after 1 min the pump is switched off
and latched in this state. The pump restarts from that state along with start of
welding.
6.9 Idle mode
The machine has an idle mode. The fan is switched off 5 min after the end of the last
welding, or after 5 min of work with decreased speed without welding. The pump is
switched off 3 min after the last welding. When oth fan and pump are switched off
the power supply lamp [4] on the front panel is linking.
6.10 OrigoTM Mig C420w PRO / OrigoTM Mig C420 PRO
The OrigoTM Mig C420w PRO / OrigoTM Mig C420 PRO is equipped with standard
control unit. Welder can manually select and adjust all welding parameters.
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SWire speed (1,9 -- 25m/min) is set with kno [12].
SThe stroke control (2/4 stroke) is selected with switch [13].
SCreep start i.e. start with 50% wire speed is toggled ON/OFF with switch [14].
SBurn ack time is set with kno [15].
The machines OrigoTM Mig C420w PRO / OrigoTM Mig C420 PRO can e fit with a
digital instrument that displays current and voltage. It incorporates a hold function
(see page 20).
7 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Maintenance must be executed by a professional.
Only those persons who have appropriate electrical knowledge (authorised
personnel) may remove the safety plates.
ote!
All guarantee undertakings from the supplier cease to apply if the customer himself
attempts any work in the product during the guarantee period in order to rectify any
faults.
7.1 Inspection and cleaning
Check regularly that the power source is free from dirt. The power source should e reg-
ularly lown clean using dry compressed air at reduced pressure. More frequently in
dirty environments. Otherwise the air inlet/outlet may ecome locked and cause over-
heating. To avoid this you can use an airfilter.
The airfilter is an accessory. Ordering num er can e found on page 20.
Welding gun
SCleaning and replacement of the welding gun’s wear parts should take place at
regular intervals in order to achieve trou le--free wire feed. Blow the wire guide
clean regularly and clean the contact tip.
The brake hub
The hu is adjusted when delivered, if
readjustment is required, follow the instructions
elow. Adjust the rake hu so that wire is slightly
slack when wire feed stops.
SAdjusting the braking torque:
STurn the red handle to the locked position.
SInsert a screwdriver into the springs in the hu .
Turn the springs clockwise to reduce the raking torque
Turn the springs anticlockwise to increase the raking torque. NB: Turn oth
springs through the same amount.
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7.2 Topping up the coolant
We recommend a 50/50 % mixture of water and ethylene glycol.
8 FAULT TRACING
Try these recommended checks and inspections before sending for an authorised
service technican.
Type of fault Actions
No arc SCheck that the mains power supply switch is turned on.
SCheck that the welding current supply and return ca les are
correctly connected.
SCheck that correct current value is set.
Welding current is interrupted
during welding
SCheck whether the thermal overload trip has operated
(indicated y the orange lamp on the front).
SCheck the main power supply fuses.
Thermal overload trips
operate frequently
SCheck to see whether the air filters are clogged.
SMake sure that you are not exceeding the rated data for the
power source (i.e. that the unit is not eing overloaded).
Poor welding performance SCheck that the welding current supply and return ca les are
correctly connected.
SCheck that the correct current value is set.
SCheck that the correct welding wires are eing used.
SCheck the main power supply fuses.
SCheck the wire feed unit -- if proper rolls are applied and
properly set the pressure of the wire feeder’s pressure rollers
9 ORDERING OF PARE PART
OrigoTM Mig C420 PRO, OrigoTM Mig C420w PRO is designed and tested in accordance
with the international and European standards IEC/EN 60974--1 and EN 60974--10. It is
the obligation of the service unit which has carried out the service or repair work to
make sure that the product still conforms to the said standard.
Spare parts may e ordered through your nearest ESAB dealer, see the last page of
this pu lication.
GB

Diagram
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C420Pdi
OrigoTM Mig C420 PRO / C420w PRO

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C420Pdi
OrigoTM Mig C420 PRO / C420w PRO
NOTE: In order to reverse output polarity on XTP see paragraph 6.2.

Origo
T
M
Mig C420 PRO, C420w PRO
Edition 070104
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C420Por
Valid for serial no. 627--XXX--XXXX
Ordering numbers
0349 302 655 OrigoTM Mig C420 PRO 400--415V 3∼
∼∼
∼50Hz
0349 303 079 OrigoTM Mig C420w PRO 400--415V 3∼
∼∼
∼50Hz; with water cooler

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document

Origo
T
M
Mig C420 PRO, C420w PRO
Edition 070104
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C420Pwe
Item Denomination Ordering no. Notes
AFeed / pressure roller
0459 052 001
0459 052 002
0459 052 003
0459 052 013
0458 825 001
0458 825 002
0458 825 003
0458 824 001
0458 824 003
Ø 0.6 & 0.8 mm; Fe, Ss & cored wire; V--groove
Ø 0.8 & 1.0 mm; Fe, Ss & cored wire; V--groove
Ø 0.9/1.0 & 1.2 mm; Fe, Ss & cored wire; V--groove
Ø 1.4 & 1.6 mm; Fe, Ss & cored wire; V--groove
Ø 0.9/1.0 & 1.2 mm; Cored wire; V--groove; knurled
Ø 1.2 & 1.4 mm; Cored wire; V--groove; knurled
Ø 1.6 & 2.0 mm; Cored wire; V--groove; knurled
Ø 0.8 & 0.9/1.0 mm; Al wire; U--groove
Ø 1.2 & 1.6 mm; Al wire; U--groove
BGear adapter 0459 441 880 Replacing 0455 053 880
CInlet nozzle 0455 049 001
DDrive gear 0459 440 001 Replacing 0455 052 001
EIntermediate nozzle 0455 072 002
0456 615 001 Fe, Ss & cored wire Al wire
FOutlet nozzle 0469 837 880
0469 837 881 Ø 2.0 mm steel for 0.6--1.6 mm Fe, Ss & cored wire Ø 2.0 mm plastic for 0.8--1.6 mm Al wire
GLiner 0349 303 018
0455 894 001 Fe, Ss & cored wire Al wire
The rollers are marked with wire dimension in mm, some are also marked with inch.
Welding with aluminium wires.
In order to weld with aluminium wires, proper rollers, nozzles and liners for
aluminium wires MUST e used. It is recommended to use 3m long welding gun for
aluminium wires, equipped with appropriate wear parts.

Origo
T
M
Mig C420 PRO, C420w PRO
Edition 070104
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C420Pwe

Origo
T
M
Mig C420 PRO, C420w PRO
Edition 070104
Accessories
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C420Pac
Digitalmeter ............................
DigitalmeterPCB .......................
0349 302 451
0349 455 934
Transformer kit for CO2heater ........... 0349 302 250
Waterflowguard ........................ 0349 302 251
Filter ................................... 0349 302 252
Cableholder ............................ 0349 303 362